Why Automation is Important in Precision Fermenters
- Arun Luthra
- Jun 9
- 4 min read
Why Automation is Important in Precision Fermenters
Precision fermentation is revolutionizing industries from biopharma to food-tech, unlocking the ability to produce proteins, enzymes, and bio-based products with unparalleled control and consistency. As the complexity of these processes grows, automation has become not just an option but a necessity.
Why Automation is Important in Precision Fermentation
Optimization of Process Parameters: Fermentation is a delicate balance of biological, chemical, and mechanical variables. Automated systems ensure that temperature, agitation, pH, and dissolved oxygen (DO) are continuously monitored and adjusted in real-time, maintaining an optimal environment for microbial or cell culture growth.
Reduction of Human Errors: Manual monitoring and intervention leave room for variability and mistakes, potentially leading to batch failures or suboptimal yields. Automation minimizes human error by delivering consistent, precise control over process parameters.
Enhanced Data Collection and Analysis: Automated fermenters log vast amounts of process data, allowing deeper insights into batch performance. This data-driven approach facilitates continuous improvement and accelerates R&D cycles.
Batch-to-Batch Consistency: For industries like biopharma and food-tech where regulatory compliance and quality assurance are paramount, automation ensures reproducibility and compliance with stringent standards.
Resource Efficiency: Automated systems optimize the use of raw materials, utilities, and labor, reducing operational costs and increasing the sustainability of production.
Scalability and Flexibility: Automation systems can be easily scaled up or down based on production needs, providing flexibility to adapt to market demands and pilot-to-production transitions.
Real-Time Decision Making: With real-time monitoring and alerts, process engineers can make quicker, data-driven decisions, preventing minor deviations from escalating into major process failures.
Compliance and Traceability: Automated systems ensure complete traceability of process parameters and interventions, simplifying compliance with cGMP, FDA, and other regulatory standards.
Integration with AI and Machine Learning: Advanced automation systems leverage AI and machine learning to predict batch outcomes, suggest process optimizations, and adapt to changing conditions dynamically, leading to improved yields and reduced process variability.
Remote Monitoring and IoT Connectivity: With IoT-enabled automation, fermentation processes can be monitored and controlled remotely. This ensures round-the-clock supervision and quick response to alarms, even from offsite locations.
Energy Management and Sustainability: Automated systems optimize energy use by dynamically adjusting aeration, agitation, and temperature controls, contributing to lower energy consumption and supporting sustainable manufacturing practices.
Key Components of Fermenter Automation
Temperature Control: Precise thermal regulation via automated heating/cooling jackets ensures the stability required for optimal biological activity.
Agitation Control: Automated control of agitation speed maintains homogeneity, oxygen transfer, and nutrient distribution.
pH Control: Automated acid/base dosing systems maintain pH within a narrow range, vital for metabolic stability.
DO Cascade Control: Automated DO control using cascade strategies balances agitation, aeration, and oxygen enrichment to maintain desired dissolved oxygen levels.
Foam Sensors and Control: Foaming is common in fermentation. Automated foam sensors detect foam presence and activate antifoam dosing systems.
Level Sensors: Automated level monitoring prevents overflow or dry-running scenarios, safeguarding equipment and product.
Backpressure Control: Maintaining constant pressure in the fermenter ensures efficient gas transfer and protects sensitive biological systems.
Major PLC Companies for Fermenter Automation
#AllenBradley (Rockwell Automation)
These companies offer robust, industry-grade Programmable Logic Controllers (PLCs) that can be customized for fermentation processes, ensuring reliability, scalability, and connectivity with SCADA and IoT systems.
Case Study: Precision Fermenter Automation
Background: A leading biotech company engaged in enzyme production faced frequent batch inconsistencies and high rejection rates due to manual monitoring.
Solution: The fermenter was retrofitted with a Siemens PLC-based automation system integrated with:
Pt100 RTDs for temperature sensing.
pH and DO probes are connected via analog input modules.
VFDs (Variable Frequency Drives) for automated agitation control.
Foam sensors coupled with peristaltic pumps for antifoam addition.
Level transmitters ensure accurate volume monitoring.
Electronic pressure sensors for precise backpressure control.
Outcome:
25% increase in batch yield.
40% reduction in batch-to-batch variability.
Reduced human intervention by 70%, allowing personnel to focus on higher-value tasks.
Real-time data acquisition enabled predictive maintenance and process optimization.
Comparison: Manual vs. Automated Fermentation Outcomes
Parameter | Manual Fermentation | Automated Fermentation |
Yield | Variable (lower yields) | Consistent (higher yields) |
Time Efficiency | High monitoring time required | Optimized, less intervention |
Labor Dependency | High manual labor | Minimal manual intervention |
Error Rate | High risk of human error | Minimal errors with automation |
Batch Consistency | Difficult to achieve | High reproducibility |
Data Logging | Manual, error-prone | Automatic, real-time |
Compliance | Complex, manual documentation | Streamlined, automated logs |
Amerging Technologies: 20 Years of Expertise in Proprietary Fermentation Software
Amerging Technologies, with two decades of pioneering experience, has been at the forefront of bioprocess automation. Our proprietary software platform integrates seamlessly with leading PLCs and SCADA systems, offering:
Real-time batch monitoring.
Advanced analytics and reporting.
Adaptive control algorithms for enhanced process stability.
Predictive insights for proactive maintenance.
IoT-enabled remote access and control.
Our deep domain expertise ensures that every fermentation process we automate achieves maximum efficiency, reproducibility, and regulatory compliance.
Amerging’s solutions have empowered countless biotech and food-tech companies globally to scale their operations with confidence, driving innovation while minimizing operational risk.
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